VEHICLE EXHAUST SYSTEM WITH RESONANCE DAMPING
A vehicle exhaust system includes an exhaust component having an outer surface and an inner surface that defines an internal exhaust component cavity. At least one bleed hole is formed in the exhaust component to reduce a resonance frequency. The bleed hole comprises a discontinuous opening into the exhaust component cavity.
The subject invention relates to a vehicle exhaust system with resonance damping to reduce noise.
BACKGROUND OF THE INVENTIONVehicle exhaust systems direct exhaust gases generated by an internal combustion engine to the external environment. These systems are comprised of various components such as pipes, converters, catalysts, filters, etc. The overall system and/or the components are capable of generating undesirable noise as a result of resonating frequencies. Different approaches have been used to address this issue.
For example, components such as mufflers, resonators, valves, etc., have been incorporated into exhaust systems in an attempt to attenuate certain resonance frequencies generated by the exhaust system. The disadvantage of adding additional components is that it is expensive and increases weight. Further, adding components introduces new sources for noise generation.
Another approach utilizes active noise control (ANC) in an attempt to attenuate the undesirable noise. ANC systems utilize components such as microphones and speakers to generate noise that cancels out the undesirable noise. ANC systems can be complex, very expensive, and can take up significant amounts of packaging space. Further, these systems are not always effective in attenuating wide ranges of resonance frequencies.
SUMMARY OF THE INVENTIONA vehicle exhaust system includes an exhaust component having an outer surface and an inner surface that defines an internal exhaust component cavity. At least one bleed hole is formed in the exhaust component to reduce a resonance frequency. The bleed hole comprises a discontinuous opening into the exhaust component cavity.
In one example, the discontinuous opening into the exhaust path is provided by a porous member that is associated with the at least one bleed hole.
In one example, the porous member comprises a sheet of microperforated material that is attached to the pipe and covers the at least one bleed hole. The sheet of microperforated material can be mounted to be flush with or offset from the pipe, for example.
In one example, the porous member comprises a boss located at the bleed hole, with the boss being formed from a powdered or sintered metal material.
In one example, the exhaust component comprises a pipe extending from a first pipe end to a second pipe end. The pipe is defined by an overall length, and the bleed hole is located at an anti-node position that is approximately 25% of the overall length from either the first or second pipe end.
In one example, the bleed hole is located at an anti-node position that is approximately 50% of the overall length from either the first or second pipe end
In one example, the exhaust component comprises a muffler having a housing extending from a first end to a second end and that provides the inner and outer surfaces to define an internal muffler volume. The muffler includes a first end cap associated with the first end and a second end cap associated with the second end. The bleed hole is located in the housing and/or within at least one of the first and second end caps.
In one example, the exhaust component comprises a Helmholtz resonator.
These and other features may be best understood from the following drawings and specification.
The exhaust components 14 and 26 can include diesel oxidation catalysts (DOC), selective catalytic reduction (SCR) catalysts, particulate filters, exhaust pipes, etc. These components 14 can be mounted in various different configurations and combinations dependent upon vehicle application and available packaging space.
The exhaust system 10 includes various acoustic features that dampen resonance frequencies generated during operation of the system. Examples of these acoustic features are discussed in detail below. These features can be used individually, or in various combinations, to provide the desired acoustical effect.
In one example, the outlet pipe 32 has an outer surface 40 and an inner surface 42 that defines an exhaust gas flow path F. The pipe 32 includes at least one bleed hole 44 that operates to reduce a resonance frequency. In one example, a plurality of bleed holes 44 can be formed within the pipe 32. The bleed hole 44 comprises a discontinuous opening into the exhaust gas flow path. The discontinuous opening comprises a porous opening or a structure that includes a plurality of small openings within a predefined area that allows a very small portion of exhaust gas to bleed out from the pipe 32.
The pipe 32 has a first pipe end 50 and a second pipe end 52 and is defined by an overall length L. The bleed holes 44 are especially effective when located with a 10-90% range of the overall length, i.e. the holes are not located at the pipe ends but are spaced by a distance that is at least 10% of the overall length from each pipe end. However, the bleed holes 44 are most effective when located near acoustic standing wave pressure anti-nodes (maximum pressure points). For example, in a first mode comprising a ½ wave mode, the bleed hole 44 would be located at a position that is approximately 50% of the overall length from either the first 50 or second 52 pipe end as indicated at 54. In other words, the bleed hole 44 is located near a mid-point of the pipe 32. A preferred range is 40-60% of the overall length. Holes located within this range provide an optimal amount of suppression.
In a second mode, comprising a full wave mode, the bleed holes 44 should be located at a position that is approximately 25% or 75% of the overall length from the first 50 and/or second 52 pipe end as indicated at 56. In other words, the bleed hole 44 would be located at a location that is a quarter of the overall length of the pipe when measured from either pipe end. Further, the first and second modes could be combined with holes located at locations 54 and 56.
A third mode could also be addressed with holes 44 being located at 12.5% or 37.5% locations within the pipe 32 as indicated at 108.
In the example shown in
In the example shown in
To provide the desired effect, an opening of a predetermined size is cut into the pipe and then the opening is covered by the sheet of microperforated material. In one example, the opening sized to be 5% or more of the cross-sectional area of the pipe at the hole location. Thus, if the cross-sectional area is 100 mm2, then the size of the opening would be 5 mm2 or larger. Preferably, the opening sized to be within 5-40% of the cross-sectional area. This allows a sufficient amount of exhaust gas to bleed out for acoustic purposes without having excessive leakage.
The sheet of microperforated material 62 can be flush mounted as indicated at 64 or can comprise a cap that is offset mounted as indicated at 66. When flush mounted, the sheet of material is formed to fit the contour of the pipe. When offset mounted the material 62 extends outwardly relative to the outer surface 40 of the pipe. The sheet of microperforated material 62 can be attached to the pipe by any of various attachment methods including welding or brazing, for example. The offset configuration provides a reduced risk of grazing flow as compared to the flush mounted configuration.
In another example, the micro-perforated cap with the offset mount 66 can be used in combination with a perforated hole 68 in the pipe.
In another example, a porous boss 70 can be formed as part of, or attached separately to, the pipe. The porous boss 70 could be formed from a powdered metal material, for example. The powdered metal material can be formed to provide the desired porosity. The entire boss can be porous as shown in
In these examples, the microperforated or porous material provides a specified amount of resistivity, i.e. material resistance (Ns/m3). In one example, material resistance is at least 25 Ns/m3. A preferred range is 50-3000 Ns/m3. In another example, the material resistance is at least 160 Ns/m3.
A hole with a continuous opening, as indicated at 76 in
In one example, a system that utilizes at least one bleed hole 44 is used with an active noise cancellation (ANC) system 88 (
As discussed above, resistive bleed holes 44 work well at pressure anti-nodes in pipes. For lumped parameter modes, pressure anti-nodes are located anywhere within the muffler 16. For muffler standing waves, pressure anti-nodes are located in muffler end caps 100, 102.
In a lumped parameter mode the exhaust gas acts like a single lumped mass with the muffler 16 acting as a spring. This is referred to as a Helmholtz resonance. As shown in
In standing wave mode, e.g. ½ waves or full waves, the exhaust gas acts like a spring. As shown in
As discussed above, the microperforated or porous material provides a specified amount of resistivity, i.e. material resistance (Ns/m3). When used in a muffler configuration, in one example, the material resistance is at least 25 Ns/m3. In another example, the material resistance is at least 160 Ns/m3. A preferred range is 50-3000 Ns/m3.
The size of the bleed hole for the muffler is determined based on muffler volume. Muffler volumes typically range from 2-3 liters for smaller vehicles up to 30-40 liters for larger vehicles. The bleed hole is preferably sized such that there is at least 25 mm2 for each liter of muffler volume. Thus, if the muffler has a 2 liter volume, the hole would be sized to be at least 50 mm2. The preferred range would be 100-1000 mm2 for each liter of muffler volume. Thus, if the muffler has a 2 liter volume, the hole would be sized to be at least 200-2000 mm2 for the preferred range. Once the hole size is selected it would then be covered with the microperforated or porous material.
The bleed holes in the mufflers can be used by themselves, or they can be used in combination with bleed holes in pipes. As discussed above, there are pressure anti-node locations for a family of resonances in the system. Lumped parameter modes (low frequencies), i.e. Helmholtz mode, have resonance damping provided by bleed holes located anywhere within the muffler (housing or end caps) as shown in
There are also velocity anti-node (velocity maximums) locations for each family of resonances as shown in
Pipe standing wave resonances are suppressed by providing an adaptive valve or other throttling valve 124 at a predetermined location within the inlet 30 or outlet 32 pipe as indicated at 122 in
Further, the ANC system 88 (
Muffler standing wave resonances are suppressed by using high resistivity baffles 130 as shown in
Pipe standing wave resonances are suppressed by providing the bleed hole(s) at a predetermined location within the side pipe 204 as indicated at 208 in
Muffler standing wave resonances are suppressed by using high resistivity baffles 210 as shown in
Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
Claims
1. A vehicle exhaust system comprising:
- an exhaust component having an outer surface and an inner surface that defines an internal exhaust component cavity; and
- at least one bleed hole formed in the exhaust component to reduce a resonance frequency, the at least one bleed hole comprising a discontinuous opening into the internal exhaust component cavity.
2. The vehicle exhaust system according to claim 1 wherein the exhaust component comprises a pipe extending from a first pipe end to a second pipe end.
3. The vehicle exhaust system according to claim 2 wherein the pipe is defined by an overall length, and wherein the at least one bleed hole is located at an anti-node position that is approximately 25% of the overall length from either the first or second pipe end.
4. The vehicle exhaust system according to claim 2 wherein the pipe is defined by an overall length, and wherein the at least one bleed hole is located at an anti-node position that is approximately 50% of the overall length from either the first or second pipe end.
5. The vehicle exhaust system according to claim 2 wherein the pipe is defined by an overall length, and wherein the at least one bleed hole comprises at least two bleed holes including a first bleed hole located at a first anti-node position that is approximately 25% of the overall length from the first pipe end and a second bleed hole located at a second anti-node position that is approximately 25% of the overall length from the second pipe end.
6. The vehicle exhaust system according to claim 2 wherein the discontinuous opening into the exhaust path is provided by a porous member that is associated with the at least one bleed hole.
7. The vehicle exhaust system according to claim 6 wherein the porous member comprises a sheet of microperforated material that is attached to the pipe and covers the at least one bleed hole.
8. The vehicle exhaust system according to claim 6 wherein the porous member comprises a boss located at the bleed hole, the boss being formed from a powdered or sintered metal material.
9. The vehicle exhaust system according to claim 2 wherein the pipe is connected to at least one additional component, and wherein the at least one bleed hole is located external to the at least one additional component such that bleed hole is open to atmosphere.
10. The vehicle exhaust system according to claim 2 wherein the pipe is connected to at least one additional component, and wherein the at least one bleed hole is located within an internal cavity defined by the additional component.
11. The vehicle exhaust system according to claim 1 wherein the exhaust component comprises a muffler having a housing extending from a first end to a second end and that provides the inner and outer surfaces to define an internal muffler volume, the muffler including a first end cap associated with the first end and a second end cap associated with the second end.
12. The vehicle exhaust system according to claim 11 wherein the at least one bleed hole is located in the housing.
13. The vehicle exhaust system according to claim 11 wherein the at least one bleed hole is located within at least one of the first and second end caps.
14. The vehicle exhaust system according to claim 11 wherein the discontinuous opening into the exhaust path is provided by a porous member that is associated with the at least one bleed hole.
15. The vehicle exhaust system according to claim 1 wherein the discontinuous opening into the exhaust path is provided by a porous member that is associated with the at least one bleed hole.
16. The vehicle exhaust system according to claim 15 wherein the porous member comprises a sheet of microperforated material that is attached to the pipe and covers the at least one bleed hole.
17. The vehicle exhaust system according to claim 16 wherein the sheet of microperforated material is flush mounted to the outer surface of the exhaust component.
18. The vehicle exhaust system according to claim 16 wherein the sheet of microperforated material is offset relative to the outer surface of the exhaust component.
19. The vehicle exhaust system according to claim 15 wherein the porous member comprises a boss located at the bleed hole, the boss being formed from a powdered or sintered metal material.
20. The vehicle exhaust system according to claim 1 including an active noise cancellation system.
21. The vehicle exhaust system according to claim 1 wherein the exhaust component comprises at least one exhaust pipe, and including a muffler connected to the at least one exhaust pipe, the muffler including a housing defining an internal muffler volume and first and second end caps attached to respective opposing ends of the housing.
22. The vehicle exhaust system according to claim 21 wherein the at least one bleed hole comprises at least a first bleed hole and a second bleed hole, the first bleed hole formed within the pipe and the second bleed hole formed within the muffler.
23. The vehicle exhaust system according to claim 21 including a valve located within the pipe.
24. The vehicle exhaust system according to claim 23 wherein the pipe is defined by an overall length, and wherein the valve is located at an anti-node position within the pipe that is approximately 25% or less of the overall length from either the first or second pipe end.
25. The vehicle exhaust system according to claim 21 including at least one baffle positioned within the internal muffler volume.
26. The vehicle exhaust system according to claim 25 wherein the at least one baffle is comprised of a microperforated material.
27. The vehicle exhaust system according to claim 25 wherein the at least one baffle supports the pipe.
28. The vehicle exhaust system according to claim 2 wherein the pipe is defined by an overall length, and wherein the at least one bleed hole is located at an anti-node position that is approximately 40-60% of the overall length from either the first or second pipe end.
29. The vehicle exhaust system according to claim 1 wherein the discontinuous opening provides a material resistance that is at least 25 Ns/m3.
30. The vehicle exhaust system according to claim 1 wherein the discontinuous opening provides a material resistance that is within a range of 50-3000 Ns/m3.
31. The vehicle exhaust system according to claim 1 wherein the discontinuous opening is formed within a pipe and comprises a hole covered by a resistive material, and wherein the hole is sized to be at least 5% of a cross-sectional area of the pipe at a hole location.
32. The vehicle exhaust system according to claim 1 wherein the discontinuous opening is formed within a pipe and comprises a hole covered by a resistive material, and wherein the hole is sized to be within a range of 5%-40% of a cross-sectional area of the pipe at a hole location.
33. The vehicle exhaust system according to claim 1 wherein the discontinuous opening is formed within a muffler and comprises a hole covered by a resistive material, and wherein the hole is sized to be at least 25 mm2 for each liter of muffler volume.
34. The vehicle exhaust system according to claim 1 wherein the discontinuous opening is formed within a muffler and comprises a hole covered by a resistive material, and wherein the hole is sized to be at least 100-1000 mm2 for each liter of muffler volume.
35. The vehicle exhaust system according to claim 1 wherein the exhaust component comprises a Helmholtz resonator.
36. The vehicle exhaust system according to claim 35 wherein the Helmholtz resonator comprises a muffler connected to a main exhaust pipe with a side pipe, and wherein the at least one bleed hole is located anywhere within the muffler.
37. The vehicle exhaust system according to claim 35 wherein the Helmholtz resonator comprises a muffler connected to a main exhaust pipe with a side pipe, and wherein the side pipe is defined by an overall length, and wherein the at least one bleed hole is located at an anti-node position that is approximately 25% of the overall length from either the first or second pipe end and/or at 50% of the overall length from either the first or second pipe end.
38. The vehicle exhaust system according to claim 35 wherein the Helmholtz resonator comprises a muffler connected to a main exhaust pipe with a side pipe, and wherein the muffler is defined by an overall length, and including at least one baffle located at a position that is approximately 25% of the overall length from either muffler end and/or at 50% of the overall length from either muffler end.
Type: Application
Filed: Feb 12, 2013
Publication Date: Dec 17, 2015
Patent Grant number: 9970340
Inventors: Kwin Abram (Columbus, IN), Joseph E. Callahan (Greenwood, IN), Tommy Pham (Avon, IN)
Application Number: 14/763,216